Textiles and methods and systems for producing textiles

ABSTRACT

Textiles are provided that include fibrous cellulosic materials having an α-cellulose content of less than about 93%, the fibrous materials being spun, woven, knitted, or entangled. The fibrous cellulosic materials can be irradiated with a dose of ionizing radiation that is sufficient to increase the molecular weight of the cellulosic materials without causing significant depolymerization of the cellulosic materials. Methods of treating textiles that include irradiating the textiles are also provided.

RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 15/411,419, filed Jan. 20, 2017, which is acontinuation of U.S. patent application Ser. No. 14/557,170, filed Dec.1, 2014, now U.S. Pat. No. 9,587,349, granted on Mar. 7, 2017, which isa continuation application of U.S. patent application Ser. No.12/417,731, filed Apr. 3, 2009, now U.S. Pat. No. 8,911,833, granted onDec. 16, 2014, which claims priority to U.S. Provisional ApplicationSer. No. 61/049,394, filed Apr. 30, 2008, and to 61/073,436, filed Jun.18, 2008. The complete disclosure of each of these applications ishereby incorporated by reference herein.

TECHNICAL FIELD

This invention relates to textiles and methods and systems for producingtextiles.

BACKGROUND

Cellulosic and lignocellulosic fibers (referred to collectively hereinas “cellulosic fibers”) have long been used to form textiles. Textilesare flexible materials formed from fibers, e.g., filaments, staplefibers, and/or yarns. Textiles are formed by a wide variety ofprocesses, including weaving, knitting, crocheting, entanglement, andpressing of fibers together (felting). Types of textiles include wovenand knitted fabrics, nonwovens, scrims, and the like. Cellulosictextiles include, for example, textiles formed from cotton, rayon, flax,jute, hemp, ramie, and other natural plant materials.

Textiles are used in a wide variety of applications, requiring manydifferent properties. For example, textile properties include resistanceto pilling, tactile characteristics such as hand, tear resistance,thermal insulating characteristics, stain and wrinkle resistance, andthe like.

SUMMARY

Many embodiments of this application use Natural Force™ Chemistry.Natural Force™ Chemistry methods use the controlled application andmanipulation of physical forces, such as particle beams, gravity, light,etc., to create intended structural and chemical molecular change. Inpreferred implementations, Natural Force™ Chemistry methods altermolecular structure without chemicals or microorganisms. By applying theprocesses of Nature, new useful matter can be created without harmfulenvironmental interference.

The invention is based, at least in part, on the discovery thatirradiating cellulosic or lignocellulosic materials, for examplecellulosic fibers, with an appropriate dose of ionizing radiationfavorably affects the physical properties of the materials, for exampleby increasing the molecular weight and level of crosslinking of at leasta cellulosic portion of the irradiated material. As a result, themechanical and/or other properties of textiles containing cellulosicmaterials can be favorably altered. For example, the tear resistance,pill resistance, charge density, wettability, bend recovery, and otherproperties of cellulosic fiber containing textiles can be increased byirradiating with ionizing radiation.

In one aspect, the invention features textiles including one or morefibrous cellulosic materials having an α-cellulose content of less thanabout 93%, the fibrous materials being spun, woven, knitted, orentangled. The fibrous cellulosic materials are irradiated, e.g., withan electron beam or other source of ionizing radiation, with a dose ofionizing radiation that is sufficient to increase the molecular weightof the cellulosic material without causing significant depolymerizationof the cellulosic material.

In another aspect, the invention features an irradiated textile that hasa molecular weight greater than an identical textile in unradiated form(i.e., subjected only to naturally-occurring levels of radiation). Invarious examples, the molecular weight of the irradiated textile is 10%,25%, 50%, 75%, 100%, 150%, 200%, 300%, or as much as 500% greater thanthe molecular weight of the textile in unradiated form.

Some implementations include one or more of the following features. Thetextiles can include yarns or fabrics. The α-cellulose content can beless than about 80%. The fibrous cellulosic materials can be selectedfrom the group consisting of flax, hemp, jute, abaca, sisal, bananafiber, coconut fiber, wheat straw, LF, ramie, bamboo fibers,cuprammonium cellulose, regenerated wood cellulose, lyocell, celluloseacetate, and blends thereof. Other useful fibers include fibers madefrom corn or other starch- or protein-containing plant or vegetablematerials such as soy, milk-based fibers, and chitin fibers made from,e.g., shrimp or crab shells. The fibrous cellulosic materials can have alignin content of at least 2%. The fibrous cellulosic materials can beirradiated prior to, during, or after being spun, woven, knitted, orentangled.

In another aspect, the invention features methods of treating a textileincluding irradiating a textile including a fibrous cellulosic materialhaving a first molecular weight with ionizing electron beam radiation,and controlling the dose of ionizing radiation so as to provide anirradiated textile including a second fibrous cellulosic material havinga second molecular weight higher than the first molecular weight.

Some implementations include any of the above features, and/or one ormore of the following features. The dose of ionizing radiation can be atleast 0.10 MRad, e.g., the dose of ionizing radiation can be controlledto a level of about 0.25 to about 2.5 MRad. Electrons in the electronbeams can have an energy of at least 0.25 MeV, e.g., from about 0.25 MeVto about 7.5 MeV. The methods can further include quenching theirradiated textiles, in some cases in the presence of a gas selected toreact with radicals present in the irradiated textiles. The fibrouscellulosic materials can include cotton.

In another aspect, the invention features methods of treating textilesincluding irradiating textiles including one or more fibrous cellulosicmaterials having a first molecular weight, and having an α-cellulosecontent of less than about 93%, with ionizing radiation, and controllingthe dose of ionizing radiation so as to provide irradiated textilesincluding a second fibrous cellulosic material having a second molecularweight higher than the first molecular weight.

Some implementations of this aspect include one or more of the followingfeatures. The dose of ionizing radiation can be at least 0.10 MRad,e.g., the dose of ionizing radiation is controlled to a level of about0.25 to about 2.5 MRad. The ionizing radiation can include an electronbeam and electrons in the electron beam can have an energy of at least0.25 MeV, e.g., from about 0.25 MeV to about 7.5 MeV. The methods canfurther include quenching the irradiated textile, in some cases in thepresence of a gas selected to react with radicals present in theirradiated textile. The textiles can include a yarn or a fabric. Thefibrous cellulosic or lignocellulosic materials can be selected from thegroup consisting of flax, hemp, jute, abaca, sisal, wheat straw, LF,ramie, bamboo fibers, cuprammonium cellulose, regenerated woodcellulose, lyocell, algae, seaweed, cellulose acetate, and blends of anyof the above materials, as well as other materials described herein. Thetextile can also include blends of these and other cellulosic andlignocellulosic materials with synthetic materials, e.g., polyethyleneand other polymers.

In another aspect, the invention features forming a garment from atextile material comprising a cellulosic material, and treating thegarment with a particle beam of sufficient energy to penetrate thetextile material. In some implementations, irradiation functionalizesthe cellulosic material. The invention also features a garmentcomprising a garment body, configured to be worn by a user. The garmentcomprises a textile comprising a cellulosic material, the cellulosicmaterial comprising a plurality of saccharide repeat units, thecellulosic material being functionalized with functional groups selectedfrom the group consisting of aldehyde groups, enol groups, nitrosogroups, nitrile groups, nitro groups, ketone groups, amino groups, alkylamino groups, alkyl groups, chloroalkyl groups, chlorofluoroalkylgroups, and carboxylic acid groups. The cellulosic material has at leastone functional group per 250 repeat units of saccharide, and may in somecases have at least one functional group per 50 repeat units or even per2 units of saccharide.

In another aspect, the invention features a method that includesirradiating a textile material that has a lignin content of at least 2%.

In a further aspect, the invention features a method comprisingirradiating a material that has been prepared by removing non-cellulosicportions of a lignocellulosic material. In some embodiments, theprepared material has a relatively high α-cellulose content, e.g.,greater than 70%, greater than 80%, or greater than 90%. The inventionalso features products made in this manner.

The term “yarn,” as used herein, refers to any long, continuous lengthof interlocked fibers, suitable for use in the production of textiles,sewing, crocheting, knitting, weaving, embroidery, and the like. Theterm “yarn” includes threads, which are a type of thin yarn which can beused, e.g., for sewing by hand or machine.

The term “fabric,” as used herein, refers to any type of fabric,including woven materials, nonwoven materials, knitted or plaitedmaterials, scrims, or any other type of materials formed from entangledfibers, filaments, and/or yarns.

The term “textile,” as used herein, refers to fabrics, and also tofibers, filaments, and yarns.

The yarn, fabric, or textile can be coated or uncoated. For example, theyarn, fabric or textile can be coated with a sizing, e.g., a starch orstarch derivative.

The full disclosures of each of the following U.S. patent applications,which are being filed concurrently herewith, are hereby incorporated byreference herein: U.S. application Ser. No. 12/417,707, now U.S. Pat.No. 7,867,358, issued on Jan. 11, 2011, U.S. application Ser. No.12/417,720, now U.S. Pat. No. 7,846,295, issued on Dec. 7, 2010, U.S.patent application Ser. No. 12/417,699, now U.S. Pat. No. 7,931,784,issued on Apr. 26, 2011, U.S. application Ser. No. 12/417,840, now U.S.Pat. No. 8,236,535, issued on Aug. 7, 2012, U.S. application Ser. No.12/417,900, U.S. application Ser. No. 12/417,880, now U.S. Pat. No.8,212,087, issued on Jul. 3, 2012, U.S. application Ser. No. 12/417,723,U.S. application Ser. No. 12/417,786, now U.S. Pat. No. 8,025,098,issued on Sep. 27, 2011, U.S. application Ser. No. 12/417,904, now U.S.Pat. No. 7,867,359, issued on Jan. 11, 2011.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. Although methods and materialssimilar or equivalent to those described herein can be used in thepractice or testing of the present invention, suitable methods andmaterials are described below. All publications, patent applications,patents, and other references mentioned herein are incorporated byreference in their entirety. In case of conflict, the presentspecification, including definitions, will control. In addition, thematerials, methods, and examples are illustrative only and not intendedto be limiting.

Other features and advantages of the invention will be apparent from thefollowing detailed description, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a diagrammatic view of a textile manufacturing system.

FIG. 2 is a diagrammatic view of a yarn manufacturing system.

FIG. 3 is a diagrammatic illustration of changing a molecular and/or asupramolecular structure of a fibrous material.

FIG. 4 is a perspective, cut-away view of a gamma irradiator housed in aconcrete vault.

FIG. 5 is an enlarged perspective view of region R of FIG. 4.

FIG. 6 is a schematic diagram of a DC accelerator.

FIG. 7 is a schematic diagram of a field ionization source.

FIG. 8 is a schematic diagram of an electrostatic ion separator.

FIG. 9 is a schematic diagram of a field ionization generator.

FIG. 10 is a schematic diagram of a thermionic emission source.

FIG. 11 is a schematic diagram of a microwave discharge ion source.

FIG. 12 is a schematic diagram of a recirculating accelerator.

FIG. 13 is a schematic diagram of a static accelerator.

FIG. 14 is a schematic diagram of a dynamic linear accelerator.

FIG. 15 is a schematic diagram of a van de Graaff accelerator.

FIG. 16 is a schematic diagram of a folded tandem accelerator.

DETAILED DESCRIPTION

As discussed herein, the invention is based, in part, on the discoverythat by irradiating fibrous materials, i.e., cellulosic andlignocellulosic materials, at appropriate levels, the molecularstructure of at least a cellulosic portion of the fibrous material canbe changed. For example, the change in molecular structure can include achange in any one or more of an average molecular weight, averagecrystallinity, surface area, polymerization, porosity, branching,grafting, and domain size of the cellulosic portion. These changes inmolecular structure can in turn result in favorable alterations of thephysical characteristics exhibited by the fibrous materials. Moreover,the functional groups of the fibrous material can be favorably altered.

Various cellulosic and lignocellulosic materials, their uses, andapplications have been described in U.S. Pat. Nos. 7,307,108, 7,074,918,6,448,307, 6,258,876, 6,207,729, 5,973,035 and 5,952,105; and in variouspatent applications, including “FIBROUS MATERIALS AND COMPOSITES,”PCT/US2006/010648, filed on Mar. 23, 2006, and “FIBROUS MATERIALS ANDCOMPOSITES,” U.S. Patent Application Publication No. 2007/0045456. Inaddition, PCT/US2007/0227, filed on Oct. 26, 2007, describes variousmethods used to pretreat cellulosic and lignocellulosic biomass tocreate materials that can be used to prepare various products andco-products. Some of these pretreated materials can be used to producestarch-based fibers, e.g., polylactic acid fibers, e.g., from corn andother starch-containing plant and vegetable materials. Theaforementioned documents are all incorporated herein by reference intheir entireties.

In addition, fibers made from chitin can be used in the methods andproducts described herein. Chitin is a polysaccharide made from units ofN-acetylglucosamine (more completely, N-acetyl-D-glucos-2-amine) thatform covalent β-1,4 linkages (similar to the linkages between glucoseunits forming cellulose). Chitin is thus a type of cellulose with onehydroxyl group on each monomer substituted with an acetylamine group.This allows for increased hydrogen bonding between adjacent polymers,giving the chitin-polymer matrix increased strength. Chitin can beobtained, for example, from shrimp, lobster, crab, and insect shells.

Relatively low doses of radiation can crosslink, graft, or otherwiseincrease the molecular weight and the degree of crosslinking of acellulosic or lignocellulosic material (e.g., cellulose) and otherfibers described herein. In some embodiments, the starting numberaverage molecular weight (prior to irradiation) of cellulosic fibers isfrom about 200,000 to about 3,200,000, e.g., from about 250,000 to about1,000,000 or from about 250,000 to about 700,000. In some embodiments,the starting number average molecular weight (prior to irradiation) ofcellulosic fibers is from about 20,000 to about 1,000,000, e.g., fromabout 25,000 to about 500,000. The number average molecular weight afterirradiation is greater than the starting number average molecularweight, for example by at least about 10%, 25%, 50%, 75%, 100%, 150%,200%, 300%, or as much as 500%. For example, if the starting numberaverage molecular weight is in the range of about 20,000 to about1,000,000, the number average molecular weight after irradiation is insome instances from about 40,000 to about 2,000,000.

As will be discussed in further detail below, the crosslinking,grafting, or otherwise increasing the molecular weight of a natural orsynthetic cellulosic material can be performed in a controlled andpredetermined manner to provide desired properties for a particularapplication, such as strength, by selecting the type or types ofradiation employed and/or dose or doses of radiation applied.

The new methods can be used to favorably alter various selectedproperties of cellulosic fibers by applying ionizing radiation atselected times and in controlled doses.

Cellulosic and other fibers having increased molecular weight can beused in making yarns, and directly in the manufacture of textiles, e.g.,as staple fibers or thread. Crosslinking, grafting, or otherwiseincreasing the molecular weight of a selected material can improve thethermal stability of the material relative to an untreated material.Increasing the thermal stability of the selected material can allow itto be processed at higher temperatures without degradation. In addition,treating the cellulosic material with radiation can sterilize thematerial, which should reduce the tendency of a fabric containing thefibers to promote the growth of fungus, mold, mildew, microorganisms, orthe like.

Ionizing radiation can also be used to control the functionalization ofthe fibrous material.

Irradiating to Increase Molecular Weight

Ionizing radiation can be applied to increase the molecular weight ofcellulosic fibers at any desired stage in textile manufacturing.Ionizing radiation can be applied to increase molecular weight, e.g.,after formation of the fibers or filaments of which the textile will becomprised, during or after formation of yarns, and before, during, orafter entanglement, knitting, or weaving of fibers to form the textile.Alternatively, or in addition, radiation can be applied, e.g., to thefinished textile or to a product made with the textile, e.g., a garment.In some embodiments, radiation is applied at more than one point duringthe manufacturing process.

For example, referring to FIG. 1, radiation can be applied to cellulosicfibers during or after yarn formation or any optional processing of thefibers or yarn, e.g., crimping, drawing, bulking, or the like.

Radiation can also be applied during nonwoven formation steps, such ascarding, entanglement, and other processing steps such as needling orapplication of binders, backings, etc. In the case of woven or knittedfabrics, radiation can be applied during or after knitting or weaving,and/or during or after any further processing such as napping, shearing,velouring, etc. For both nonwovens and knitted or woven fabrics,radiation can be applied to the finished textile or to an articlemanufactured from the textile, e.g., a garment. It is generallypreferable that the fibers, yarn, or fabric be in a relatively dry stateduring irradiation. Without wishing to be bound to theory, it isbelieved that irradiating the material in a relatively dry state helpsto prevent chain cleavage of the cellulosic material. For example, themoisture content can be less than about 7.5%, e.g., less than 5%, 4%,3%, 2%, 1.5% or 1%. In some cases, the moisture content may be in therange of 2% to 6%.

As will be discussed in further detail below, radiation can be appliedto the finished textile in a manner so as to favorably affect thefunctional groups present within and/or on the surface of the textile.

Irradiating to Affect Material Functional Groups

After treatment with one or more ionizing radiations, such as photonicradiation (e.g., X-rays or gamma-rays), e-beam radiation, or irradiationwith particles heavier than electrons that are positively or negativelycharged (e.g., protons or carbon ions), any of thecarbohydrate-containing materials or mixtures described herein becomeionized; that is, they include radicals at levels that are detectable,for example, with an electron spin resonance spectrometer. Afterionization, any material that has been ionized can be quenched to reducethe level of radicals in the ionized material, e.g., such that theradicals are no longer detectable with the electron spin resonancespectrometer. For example, the radicals can be quenched by theapplication of a sufficient pressure to the ionized material and/or bycontacting the ionized material with a fluid, such as a gas or liquid,that reacts with (quenches) the radicals. Various gases, for examplenitrogen or oxygen, or liquids, can be used to at least aid in thequenching of the radicals and to functionalize the ionized material withdesired functional groups. Thus, irradiation followed by quenching canbe used to provide a material with desired functional groups, includingfor example one or more of the following: aldehyde groups, enol groups,nitroso groups, nitrile groups, nitro groups, ketone groups, aminogroups, alkyl amino groups, alkyl groups, chloroalkyl groups,chlorofluoroalkyl groups, and/or carboxylic acid groups. These groupsincrease the hydrophilicity of the region of the material where they arepresent. In some implementations, the material is irradiated andquenched, before or after processing steps such as dyeing and sizing, toaffect the functionality within and/or at the surface of the materialand thereby affect properties of the material such as the receptivity ofthe material surface to sizes, dyes, coatings, and the like, and theadherence of sizes, dyes, coatings, and the like to the material.

Functionalization can also favorably change the charge density of thetextile. This can be advantageous in certain applications, for examplewhen the irradiated, charged fibers are used in filter materials such asair filters, e.g., HEPA filters, and cigarette filters. In the case ofHEPA filters, the fibers are typically randomly deposited in a mat,while in the case of cigarette filters long fibers are typicallyarranged in a bundle or tow. When a particle moves through a mat or towof charged fibers the particle touches the charged fibers. This causesthe particle surface to become more polarized and to be attracted to thefiber surface. As a result, the particle will lose more speed (inertia)at each collision with a charged fiber. This can allow a filter havingcharged fibers to catch as many particles as a filter with a relativelyhigher fiber content but only uncharged particles. Fewer fibers in thefilter can reduce cost and create a more open structure within thefilter, decreasing resistance to airflow without reducing filterefficiency.

In some implementations, functionalization can enhance moisture regain(as measured according to ASTM D2495), e.g., the moisture regain of thetextile can be increased by at least 5%, 10%, 25%, 50%, 100%, 250%, or500% relative to untreated cellulosic material. This increase inmoisture regain can be significant in enhancing wicking action, bendrecovery, and resistance to static electricity.

Functionalization can also enhance the work recovery of cellulosicfibers (as measured according to ASTM D1774-94), e.g., by at least 5%,10%, 25%, 50%, 100%, 250%, or 500% relative to untreated cellulosicmaterial. The work recovery of the fibers can affect the wrinkleresistance of a fabric formed from the cellulosic material, with anincrease in work recovery generally enhancing wrinkle resistance.

Functionalization can also increase the decomposition temperature of thecellulosic material or a textile formed from the cellulosic material,e.g., by at least 3, 5, 10 or 25 degrees C. The decompositiontemperature is measured by TGA in an air atmosphere, for example usingIPC-TM-650 of the Institute for Interconnecting and Packaging ElectronicCircuits, which references ASTM D 618 and D 3850.

FIG. 3 illustrates changing a molecular and/or a supramolecularstructure of cellulosic fibers by treating the fibers with ionizingradiation, such as with electrons or ions of sufficient energy to ionizethe material, to provide a first level of radicals. As shown in FIG. 3,if the ionized material remains in the atmosphere, it will be oxidized,e.g., to an extent that carboxylic acid groups are generated by reactingwith the atmospheric oxygen. Since the radicals can “live” for some timeafter irradiation, e.g., longer than 1 day, 5 days, 30 days, 3 months, 6months, or even longer than 1 year, material properties can continue tochange over time, which in some instances can be undesirable. However,in some cases this can be desirable, for example in the case of filtermaterials. In filter materials the presence of radicals over a longperiod of time can provide extended filter life.

Detecting radicals in irradiated samples by electron spin resonancespectroscopy and radical lifetimes in such samples is discussed inBartolotta et al., Physics in Medicine and Biology, 46 (2001), 461-471and in Bartolotta et al., Radiation Protection Dosimetry, Vol. 84, Nos.1-4, pp. 293-296 (1999). As shown in FIG. 3, the ionized material can bequenched to functionalize and/or to stabilize the ionized material.

In some embodiments, quenching includes an application of pressure tothe ionized material, such as by mechanically deforming the material,e.g., directly mechanically compressing the material in one, two, orthree dimensions, or applying pressure to a fluid in which the materialis immersed, e.g., isostatic pressing. In such instances, thedeformation of the material itself brings radicals, which are oftentrapped in crystalline domains, in close enough proximity so that theradicals can recombine, or react with another group. In some instances,the pressure is applied together with the application of heat, such as asufficient quantity of heat to elevate the temperature of the materialto above a melting point or softening point of a component of theionized material, such as lignin, cellulose or hemicellulose. Heat canimprove molecular mobility in the material, which can aid in thequenching of the radicals. When pressure is utilized to quench, thepressure can be greater than about 1000 psi, such as greater than about1250 psi, 1450 psi, 3625 psi, 5075 psi, 7250 psi, 10000 psi, or evengreater than 15000 psi.

In some embodiments, quenching includes contacting the ionized materialwith a fluid, such as a liquid or gas, e.g., a gas capable of reactingwith the radicals, such as acetylene or a mixture of acetylene innitrogen, ethylene, chlorinated ethylenes or chlorofluoroethylenes,propylene or mixtures of these gases. In other particular embodiments,quenching includes contacting the ionized material with a liquid, e.g.,a liquid soluble in, or at least capable of penetrating into the ionizedmaterial and reacting with the radicals, such as a diene, such as1,5-cyclooctadiene. In some specific embodiments, the quenching includescontacting the ionized material with an antioxidant, such as Vitamin E.If desired, the material can include an antioxidant dispersed therein,and the quenching can come from contacting the antioxidant dispersed inthe material with the radicals.

Other methods for quenching are possible. For example, any method forquenching radicals in polymeric materials described in Muratoglu et al.,U.S. Patent Application Publication No. 2008/0067724 and Muratoglu etal., U.S. Pat. No. 7,166,650, the disclosures of which are incorporatedby reference herein in their entireties, can be utilized for quenchingany ionized material described herein. Furthermore any quenching agent(described as a “sensitizing agent” in the above-noted Muratogludisclosures) and/or any antioxidant described in either Muratoglureference can be utilized to quench any ionized material.

Functionalization can be enhanced by utilizing heavy charged ions, suchas any of the heavier ions described herein. For example, if it isdesired to enhance oxidation, charged oxygen ions can be utilized forthe irradiation. If nitrogen functional groups are desired, nitrogenions or any ion that includes nitrogen can be utilized. Likewise, ifsulfur or phosphorus groups are desired, sulfur or phosphorus ions canbe used in the irradiation.

In some embodiments, after quenching any of the quenched ionizedmaterials described herein can be further treated with one or morefurther doses of radiation, such as ionizing or non-ionizing radiation,sonication, pyrolysis, and oxidation for additional molecular and/orsupramolecular structure change.

In some embodiments, the fibrous material is irradiated under a blanketof an inert gas, e.g., helium or argon, prior to quenching.

In some cases, the materials can be exposed to a particle beam in thepresence of one or more additional fluids (e.g., gases and/or liquids).Exposure of a material to a particle beam in the presence of one or moreadditional fluids can increase the efficiency of the treatment.

In some embodiments, the material is exposed to a particle beam in thepresence of a fluid such as air. Particles accelerated in any one ormore of the types of accelerators disclosed herein (or another type ofaccelerator) are coupled out of the accelerator via an output port(e.g., a thin membrane such as a metal foil), pass through a volume ofspace occupied by the fluid, and are then incident on the material. Inaddition to directly treating the material, some of the particlesgenerate additional chemical species by interacting with fluid particles(e.g., ions and/or radicals generated from various constituents of air,such as ozone and oxides of nitrogen). These generated chemical speciescan also interact with the material, and can act as initiators for avariety of different chemical bond-breaking reactions in the material.For example, any oxidant produced can oxidize the material, which canresult in molecular weight reduction. In certain embodiments, additionalfluids can be selectively introduced into the path of a particle beambefore the beam is incident on the material. As discussed above,reactions between the particles of the beam and the particles of theintroduced fluids can generate additional chemical species, which reactwith the material and can assist in functionalizing the material, and/orotherwise selectively altering certain properties of the material. Theone or more additional fluids can be directed into the path of the beamfrom a supply tube, for example. The direction and flow rate of thefluid(s) that is/are introduced can be selected according to a desiredexposure rate and/or direction to control the efficiency of the overalltreatment, including effects that result from both particle-basedtreatment and effects that are due to the interaction of dynamicallygenerated species from the introduced fluid with the material. Inaddition to air, exemplary fluids that can be introduced into the ionbeam include oxygen, nitrogen, one or more noble gases, one or morehalogens, and hydrogen.

The location of the functional groups can be controlled by, for example,selecting a particular type and dose of ionizing particles. For example,gamma radiation tends to affect the functionality of molecules withinthe material, while electron beam radiation tends to preferentiallyaffect the functionality of molecules at the surface.

In some cases, functionalization of the material can occursimultaneously with irradiation, rather than as a result of a separatequenching step. In this case, the type of functional groups and degreeof oxidation can be affected in various ways, for example by controllingthe gas blanketing the material to be irradiated, through which theirradiating beam passes. Suitable gases include nitrogen, oxygen, air,ozone, nitrogen dioxide, sulfur dioxide, and chlorine.

In some embodiments, functionalization results in the formation of enolgroups in the fibrous material. This can enhance the receptivity of thefunctionalized material to inks, dyes, sizes, coatings, and the like,and can provide grafting sites.

Cooling Irradiated Materials

During treatment of the materials discussed above with ionizingradiation, especially at high dose rates, such as at rates greater then0.15 Mrad per second, e.g., 0.25 Mrad/s, 0.35 Mrad/s, 0.5 Mrad/s, 0.75Mrad/s or even greater than 1 Mrad/sec, the materials can retainsignificant quantities of heat so that the temperature of the materialbecomes elevated. While higher temperatures can, in some embodiments, beadvantageous, e.g., when a faster reaction rate is desired, it isadvantageous to control the heating to retain control over the chemicalreactions initiated by the ionizing radiation, such as crosslinking,chain scission and/or grafting, e.g., to maintain process control.

For example, in one method, the material is irradiated at a firsttemperature with ionizing radiation, such as photons, electrons or ions(e.g., singularly or multiply charged cations or anions), for asufficient time and/or a sufficient dose to elevate the material to asecond temperature higher than the first temperature. The irradiatedmaterial is then cooled to a third temperature below the secondtemperature. If desired, the cooled material can be treated one or moretimes with radiation, e.g., with ionizing radiation. If desired, coolingcan be applied to the material after and/or during each radiationtreatment.

Cooling can in some cases include contacting the material with a fluid,such as a gas, at a temperature below the first or second temperature,such as gaseous nitrogen at or about 77 K. Even water, such as water ata temperature below nominal room temperature (e.g., 25 degrees Celsius)can be utilized in some implementations.

Types of Radiation

The radiation can be provided by, e.g., 1) heavy charged particles, suchas alpha particles, oxygen particles, or protons, 2) electrons,produced, for example, in beta decay or electron beam accelerators, or3) electromagnetic radiation, for example, gamma rays, X rays, orultraviolet rays. Different forms of radiation ionize the material viaparticular interactions, as determined by the energy of the radiation.The radiation may be in the form of a particle beam of elementaryparticles, e.g., electrons, protons, alpha particles, and the like. Insome implementations, the particle beam has sufficient energy topenetrate the cross-section of the material that is being irradiated. Inembodiments that use electrons, the electrons can have a speed of, forexample, 0.5 c to 99.9 c. Heavier particles, e.g., protons, generallyhave a speed of less than 0.5 c. Because heavier particles typicallyhave lower speeds, less shielding is generally required than is neededfor electron beams.

Heavy charged particles primarily ionize matter via Coulomb scattering;furthermore, these interactions produce energetic electrons that canfurther ionize matter. Alpha particles are identical to the nucleus of ahelium atom and are produced by the alpha decay of various radioactivenuclei, such as isotopes of bismuth, polonium, astatine, radon,francium, radium, several actinides, such as actinium, thorium, uranium,neptunium, curium, californium, americium, and plutonium.

Electrons interact via Coulomb scattering and bremssthrahlung radiationproduced by changes in the velocity of electrons. Electrons can beproduced by radioactive nuclei that undergo beta decay, such as isotopesof iodine, cesium, technetium, and iridium. Alternatively, an electrongun can be used as an electron source via thermionic emission.

Electromagnetic radiation interacts via three processes: photoelectricabsorption, Compton scattering, and pair production. The dominatinginteraction is determined by the energy of the incident radiation andthe atomic number of the material. The summation of interactionscontributing to the absorbed radiation in cellulosic material can beexpressed by the mass absorption coefficient.

Electromagnetic radiation is subclassified as gamma rays, x rays,ultraviolet rays, infrared rays, microwaves, or radiowaves, depending onits wavelength.

For example, gamma radiation can be employed to irradiate the materials.Referring to FIGS. 4 and 5 (an enlarged view of region R), a gammairradiator 10 includes gamma radiation sources 408, e.g., ⁶⁰Co pellets,a working table 14 for holding the materials to be irradiated andstorage 16, e.g., made of a plurality iron plates, all of which arehoused in a concrete containment chamber (vault) 20 that includes a mazeentranceway 22 beyond a lead-lined door 26. Storage 16 includes aplurality of channels 30, e.g., sixteen or more channels, allowing thegamma radiation sources to pass through storage on their way proximatethe working table.

In operation, the sample to be irradiated is placed on a working table.The irradiator is configured to deliver the desired dose rate andmonitoring equipment is connected to an experimental block 31. Theoperator then leaves the containment chamber, passing through the mazeentranceway and through the lead-lined door. The operator mans a controlpanel 32, instructing a computer 33 to lift the radiation sources 12into working position using cylinder 36 attached to a hydraulic pump 40.

Gamma radiation has the advantage of a significant penetration depthinto a variety of materials in the sample. Sources of gamma rays includeradioactive nuclei, such as isotopes of cobalt, calcium, technicium,chromium, gallium, indium, iodine, iron, krypton, samarium, selenium,sodium, thalium, and xenon.

Sources of x rays include electron beam collision with metal targets,such as tungsten or molybdenum or alloys, or compact light sources, suchas those produced commercially by Lyncean.

Sources for ultraviolet radiation include deuterium or cadmium lamps.

Sources for infrared radiation include sapphire, zinc, or selenidewindow ceramic lamps.

Sources for microwaves include klystrons, Slevin type RF sources, oratom beam sources that employ hydrogen, oxygen, or nitrogen gases.

In some embodiments, a beam of electrons is used as the radiationsource. A beam of electrons has the advantages of high dose rates (e.g.,1, 5, or even 10 Mrad per second), high throughput, less containment,and less confinement equipment. In addition, electrons having energiesof 4-10 MeV can have a penetration depth of 5 to 30 mm or more, such as40 mm.

Electron beams can be generated, e.g., by electrostatic generators,cascade generators, transformer generators, low energy accelerators witha scanning system, low energy accelerators with a linear cathode, linearaccelerators, and pulsed accelerators. Electrons as an ionizingradiation source can be useful, e.g., for relatively thin materials,e.g., less than 0.5 inch, e.g., less than 0.4 inch, 0.3 inch, 0.2 inch,or less than 0.1 inch. In some embodiments, the energy of each electronof the electron beam is from about 0.25 MeV to about 7.5 MeV (millionelectron volts), e.g., from about 0.5 MeV to about 5.0 MeV, or fromabout 0.7 MeV to about 2.0 MeV. Electron beam irradiation devices may beprocured commercially from Ion Beam Applications, Louvain-la-Neuve,Belgium or the Titan Corporation, San Diego, Calif. Typical electronenergies can be 1, 2, 4.5, 7.5, or 10 MeV. Typical electron beamirradiation device power can be 1, 5, 10, 20, 50, 100, 250, or 500 kW.Typical doses can take values of 1, 5, 10, 20, 50, 100, or 200 kGy.

Tradeoffs in considering electron beam irradiation device powerspecifications include operating costs, capital costs, depreciation, anddevice footprint. Tradeoffs in considering exposure dose levels ofelectron beam irradiation would be energy costs and environment, safety,and health (ESH) concerns. Typically, generators are housed in a vault,e.g., of lead or concrete.

The electron beam irradiation device can produce either a fixed beam ora scanning beam. A scanning beam may be advantageous with large scansweep length and high scan speeds, as this would effectively replace alarge, fixed beam width. Further, available sweep widths of 0.5 m, 1 m,2 m or more are available.

In embodiments in which the irradiating is performed withelectromagnetic radiation, the electromagnetic radiation can have anenergy per photon (in electron volts) of, for example, greater than 10²eV, e.g., greater than 10³, 10⁴, 10⁵, 10⁶, or even greater than 10⁷ eV.In some embodiments, the electromagnetic radiation has energy per photonof between 10⁴ and 10⁷, e.g., between 10⁵ and 10⁶ eV. Theelectromagnetic radiation can have a frequency of, e.g., greater than10¹⁶ hz, greater than 10¹⁷ hz, 10¹⁸, 10¹⁹, 10²⁰, or even greater than10²¹ hz. In some embodiments, the electromagnetic radiation has afrequency of between 10¹⁸ and 10²² Hz, e.g., between 10¹⁹ to 10²¹ Hz.

One type of accelerator that can be used to accelerate ions producedusing the sources discussed above is a Dynamitron® (available, forexample, from Radiation Dynamics Inc., now a unit of IBA,Louvain-la-Neuve, Belgium). A schematic diagram of a Dynamitron®accelerator 1500 is shown in FIG. 6. Accelerator 1500 includes aninjector 1510 (which includes an ion source), and an accelerating column1520 that includes a plurality of annular electrodes 1530. Injector 1510and column 1520 are housed within an enclosure 1540 that is evacuated bya vacuum pump 1600.

Injector 1510 produces a beam of ions 1580, and introduces beam 1580into accelerating column 1520. The annular electrodes 1530 aremaintained at different electric potentials, so that ions areaccelerated as they pass through gaps between the electrodes (e.g., theions are accelerated in the gaps, but not within the electrodes, wherethe electric potentials are uniform). As the ions travel from the top ofcolumn 1520 toward the bottom in FIG. 6, the average speed of the ionsincreases. The spacing between subsequent annular electrodes 1530typically increases, therefore, to accommodate the higher average ionspeed.

After the accelerated ions have traversed the length of column 1520, theaccelerated ion beam 1590 is coupled out of enclosure 1540 throughdelivery tube 1555. The length of delivery tube 1555 is selected topermit adequate shielding (e.g., concrete shielding) to be positionedadjacent to column 1520 to isolate the column. After passing throughtube 1555, ion beam 1590 passes through scan magnet 1550. Scan magnet1550, which is controlled by an external logic unit (not shown), cansweep accelerated ion beam 1590 in controlled fashion across atwo-dimensional plane oriented perpendicular to a central axis of column1520. As shown in FIG. 6, ion beam 1590 passes through window 1560(e.g., a metal foil window or screen) and then is directed to impinge onselected regions of a sample 1570 by scan magnet 1550.

In some embodiments, the electric potentials applied to electrodes 1530are static potentials generated, for example, by DC potential sources.In certain embodiments, some or all of the electric potentials appliedto electrodes 1530 are variable potentials generated by variablepotential sources. Suitable variable sources of large electricpotentials include amplified field sources such as klystrons, forexample. Accordingly, depending upon the nature of the potentialsapplied to electrodes 1530, accelerator 1500 can operate in eitherpulsed or continuous mode.

To achieve a selected accelerated ion energy at the output end of column1520, the length of column 1520 and the potentials applied to electrodes1530 are chosen based on considerations that are well-known in the art.However, it is notable that to reduce the length of column 1520,multiply-charged ions can be used in place of singly-charged ions. Thatis, the accelerating effect of a selected electric potential differencebetween two electrodes is greater for an ion bearing a charge ofmagnitude 2 or more than for an ion bearing a charge of magnitude 1.Thus, an arbitrary ion X²⁺ can be accelerated to a final energy E over ashorter length than a corresponding arbitrary ion X⁺. Triply- andquadruply-charged ions (e.g., X³⁺ and X⁴⁺) can be accelerated to finalenergy E over even shorter distances. Therefore, the length of column1520 can be significantly reduced when ion beam 1580 includes primarilymultiply-charged ion species.

To accelerate positively-charged ions, the potential differences betweenelectrodes 1530 of column 1520 are selected so that the direction ofincreasing field strength in FIG. 6 is downward (e.g., toward the bottomof column 1520). Conversely, when accelerator 1500 is used to acceleratenegatively-charged ions, the electric potential differences betweenelectrodes 1530 are reversed in column 1520, and the direction ofincreasing field strength in FIG. 6 is upward (e.g., toward the top ofcolumn 1520). Reconfiguring the electric potentials applied toelectrodes 1530 is a straightforward procedure, so that accelerator 1500can be converted relatively rapidly from accelerating positive ions toaccelerating negative ions, or vice versa. Similarly, accelerator 1500can be converted rapidly from accelerating singly-charged ions toaccelerating multiply-charged ions, and vice versa.

Doses

In some embodiments, the irradiating (with any radiation source or acombination of sources) is performed until the material receives a doseof at least 0.05 MRad, e.g., at least 0.1 MRad, at least 0.25 MRad, atleast 0.5 MRad, at least 0.75 MRad, at least 1.0 MRad, at least 1.5,MRad, at least 2.0 MRad, at least 2.5 MRad, at least 3.0 MRad, at least4.0 MRad, at least 5.0 MRad, or at least 10.0 MRad. In some embodiments,the irradiating is performed until the material receives a dose ofbetween 1.0 MRad and 6.0 MRad, e.g., between 1.5 MRad and 4.0 MRad. Insome embodiments, a preferred dose is from about 0.25 to about 5 MRad.The dose is selected so as to be sufficient to increase the molecularweight of the cellulosic material, e.g., by cross-linking the cellulosechains, while being sufficiently low so as not to depolymerize orotherwise deleteriously affect the cellulosic material.

The doses discussed above are also suitable for functionalization of thematerial, with the degree of functionalization generally being higherthe higher the dose.

In some embodiments, the irradiating is performed at a dose rate ofbetween 5.0 and 1500.0 kilorads/hour, e.g., between 10.0 and 750.0kilorads/hour or between 50.0 and 350.0 kilorads/hours. When highthroughput is desired, radiation can be applied at, e.g., 0.5 to 3.0MRad/sec, or even faster, using cooling to avoid overheating theirradiated material.

It can be desirable to irradiate multiple times to achieve a given finaldose, e.g., by delivering a 1 MRad dose 10 times, to provide a finaldose of 10 MRad. This may prevent overheating of the irradiatedmaterial, particularly if the material is cooled between doses.

If gamma radiation is utilized as the radiation source, a dose of fromabout 1 Mrad to about 10 Mrad, e.g., from about 1.5 Mrad to about 7.5Mrad or from about 2.0 Mrad to about 5.0 Mrad, can be applied.

If e-beam radiation is utilized, a smaller dose can be utilized(relative to gamma radiation), such as a dose of from about 0.1 Mrad toabout 5 Mrad, e.g., between about 0.2 Mrad to about 3 Mrad, or betweenabout 0.25 Mrad and about 2.5 Mrad.

In some embodiments, two or more radiation sources are used, such as twoor more ionizing radiations. For example, samples can be treated, in anyorder, with a beam of electrons, followed by gamma radiation and UVlight having wavelengths from about 100 nm to about 280 nm. In someembodiments, samples are treated with three ionizing radiation sources,such as a beam of electrons, gamma radiation, and energetic UV light.

Types of Cellulosic Textiles

Suitable cellulosic materials include materials that have an α-celluloselevel of less than about 93% by weight, preferably less than about 90%,for example less than about 85%. The balance of the cellulosic materialis generally comprised of lignin, hemicellulose, pectin, and othernaturally occurring substances. For example, flax fiber obtained fromnatural (non-transgenically modified) flax plants has an α-cellulosecontent of about 70%, with the balance being hemicellulose, lignin, andpectin.

It is generally also preferred that the cellulosic material have alignin content of at least 2%, in some cases at least 5%, at least 10%or at least 20%. Without wishing to be bound by theory, the inventorsbelieve that lignin, a high molecular weight three-dimensional molecule,acts as a plasticizer and anti-oxidant and tends to stabilize thecellulosic material during and after irradiation, e.g., in the 0.5 to 5MRad range.

In some implementations, lignin may be added to the textile as anadditive. For example, lignin can be applied to the textile or startingcellulosic material in a manner so as to penetrate the cellulosicmaterial. In some cases, lignin will cross-link during irradiation,enhancing the properties of the irradiated product. In someimplementations, lignin is added to increase the lignin content of acellulosic material that has a relatively low lignin content in itsnatural state. For example up to 1, 2, 3, 4, 5, 7.5, 10, 15, 20, or even25% by weight of lignin can be added. The lignin can be added as asolid, e.g., as a powder or other particulate material, or can bedissolved or dispersed and added in liquid form. In the latter case, thelignin can be dissolved in solvent or a solvent system. The solvent orsolvent system can be in the form of a single phase or two or morephases. Solvent systems for cellulosic and lignocellulosic materialsinclude DMSO-salt systems. Such systems include, for example, DMSO incombination with a lithium, magnesium, potassium, sodium or zinc salt.Lithium salts include LiCl, LiBr, LiI, lithium perchlorate and lithiumnitrate. Magnesium salts include magnesium nitrate and magnesiumchloride. Potassium salts include potassium iodide and nitrate. Examplesof sodium salts include sodium iodide and nitrate. Examples of zincsalts include zinc chloride and nitrate. Any salt can be anhydrous orhydrated. Typical loadings of the salt in the DMSO are between about 1and about 50 percent, e.g., between about 2 and 25, between about 3 and15 or between about 4 and 12.5 percent by weight.

In some cases, lignin will cross-link in the paper during irradiation,further enhancing the physical properties of the textile material.

Some suitable cellulosic materials have a hemicellulose content of atleast 5%, in some cases at least 10% or at least 20%.

The compositions of certain cellulosic fibers are given in Table 1below.

TABLE 1 Fiber Cellulose Lignin Hemicellulose Flax 71 2 19 Hemp 75 4 18Jute 72 13 13 Abaca 70 6 22 Sisal 73 11 13 Cotton 93 . . . 3 Wheat Straw51 16 26 “LF” (lignocellulose 58 31 8 filler -- a byproduct ofindustrial wheat straw fractionation) From “Effects of Lignin Content onthe Properties of Lignocellulose-based Biocomposites,” Le Digabel etal., Carbohydrate Polymers, 2006.

The cellulose chains in the cellulosic material can be unmodified, i.e.,that no synthetic polymer be grafted to the cellulosic chains before orduring irradiation.

Suitable cellulosic and lignocellulosic materials include, but are notlimited to, for example, cotton, flax (e.g., linen), hemp, jute, abaca,sisal, wheat straw, LF, ramie, bamboo fibers, algae, seaweed,cuprammonium cellulose (rayon), regenerated wood cellulose, lyocell,cellulose acetate, and blends thereof. Other fiber source materials suchas corn, milk, soy, and chitin, have been discussed elsewhere herein.

In some cases, cellulosic or lignocellulosic material is dissolved in asolvent or solvent system and spun or extruded to form fibers orfilaments. The solvent or solvent system can be in the form of a singlephase or two or more phases. Solvent systems for cellulosic andlignocellulosic materials include the DMSO-salt systems discussed above.Spinning or extrusion can be accomplished, for example, using techniqueswell known in the textile field. The cellulosic or lignocellulosicmaterial can be irradiated, and/or the solution or the fibers orfilaments can be irradiated.

The cellulose material can be in the form of fibers, staple fibers,filaments, yarns, or fabrics. Fabrics include nonwovens, wovens andknitted fabrics. The fibers may have a high aspect ratio (L/D). Forexample, the average length-to-diameter ratio of the fibers can begreater than 8/1, e.g., greater than 10/1, greater than 15/1, greaterthan 20/1, greater than 25/1, or greater than 50/1. An average length ofthe fibers can be, e.g., between about 0.5 mm and 2.5 mm, e.g., betweenabout 0.75 mm and 1.0 mm, and an average width (i.e., diameter) of thefibers can be, e.g., between about 5 μm and 50 μm, e.g., between about10 μm and 30 μm.

The fiber, yarn, or fabric can have a relatively low bulk density, toallow easier penetration by particles and thus faster throughput. Thebulk density can be, for example, about 0.1 to 0.5 g/cm³, e.g., about0.3 to 0.15 g/cm³. Low bulk density also facilitates cooling of thematerial when the material is heated by irradiation. In someimplementations, the fibers have a relatively small diameter, forexample, an average diameter of about 1-500 microns, e.g., 5-150microns, or 25-100 microns. These small fiber diameters generallyprovide the textile with a low bulk density and good airflow, which canprovide cooling during irradiation.

Textile Additives

Any of the many additives and coatings used in the textile industry canbe added to or applied to the fibrous materials, fabrics, or any othermaterials and products described herein.

Additives include fillers such as calcium carbonate, plastic pigments,graphite, wollastonite, mica, glass, fiber glass, silica, and talc;inorganic flame retardants such as alumina trihydrate or magnesiumhydroxide; organic flame retardants such as chlorinated or brominatedorganic compounds; carbon fibers; metal fibers or powders (e.g.,aluminum, stainless steel). These additives can reinforce, extend, orchange electrical, mechanical, compatibility or other properties. Otheradditives include starch, lignin, fragrances, coupling agents,antioxidants, opacifiers, heat stabilizers, colorants such as dyes andpigments, polymers, e.g., degradable polymers, photostabilizers, andbiocides. Representative degradable polymers include polyhydroxy acids,e.g., polylactides, polyglycolides and copolymers of lactic acid andglycolic acid, poly(hydroxybutyric acid), poly(hydroxyvaleric acid),poly[lactide-co-(e-caprolactone)], poly[glycolide-co-(e-caprolactone)],polycarbonates, poly(amino acids), poly(hydroxyalkanoate)s,polyanhydrides, polyorthoesters and blends of these polymers.

Additives that can in some cases be cross-linked by irradiation, e.g.,lignin and sizing such as starch, may be added or applied to the textilebefore and/or after irradiation.

When described additives are included, they can be present in amounts,calculated on a dry weight basis, of from below about 1 percent to ashigh as about 15 percent, based on total weight of the fibrous material.More typically, amounts range from between about 0.5 percent to about7.5 percent by weight.

Any additives described herein can be encapsulated, e.g., spray dried ormicroencapsulated, e.g., to protect the additives from heat or moistureduring handling.

Suitable coatings include any of the many coatings used in the textileindustry to provide specific surface characteristics, includingperformance characteristics required for particular types of garments orother applications. For example, the textile may include a waterproof orwater-resistant coating.

As mentioned above, various fillers can be included in the fibers,yarns, textiles or finished products. These fillers may serve, forexample, as frictionizing agents, in sizings, as flameproofing orfireproofing agents, for thermal protection, and to impart waterrepellency. For example, inorganic fillers such as calcium carbonate(e.g., precipitated calcium carbonate or natural calcium carbonate),aragonite clay, orthorhombic clays, calcite clay, rhombohedral clays,kaolin clay, bentonite clay, dicalcium phosphate, tricalcium phosphate,calcium pyrophosphate, insoluble sodium metaphosphate, precipitatedcalcium carbonate, magnesium orthophosphate, trimagnesium phosphate,hydroxyapatites, synthetic apatites, alumina, silica xerogel, metalaluminosilicate complexes, sodium aluminum silicates, zirconiumsilicate, silicon dioxide, or combinations of the inorganic additivescan be used. The fillers can have, e.g., a particle size of greater than1 micron, e.g., greater than 2 micron, 5 micron, 10 micron, 25 micron oreven greater than 35 microns.

Nanometer scale fillers can also be used alone, or in combination withfibrous materials of any size and/or shape. The fillers can be in theform of, e.g., a particle, a plate or a fiber. For example, nanometersized clays, silicon and carbon nanotubes, and silicon and carbonnanowires can be used. The filler can have a transverse dimension lessthan 1000 nm, e.g., less than 900 nm, 800 nm, 750 nm, 600 nm, 500 nm,350 nm, 300 nm, 250 nm, 200 nm, less than 100 nm, or even less than 50nm.

In some embodiments, the nano-clay is a montmorillonite. Such clays areavailable from Nanocor, Inc. and Southern Clay products, and have beendescribed in U.S. Pat. Nos. 6,849,680 and 6,737,464. The clays can besurface treated before mixing into, e.g., a resin or a fibrous material.For example, the clay can be surface is treated so that its surface isionic in nature, e.g., cationic or anionic.

Aggregated or agglomerated nanometer scale fillers, or nanometer scalefillers that are assembled into supramolecular structures, e.g.,self-assembled supramolecular structures can also be used. Theaggregated or supramolecular fillers can be open or closed in structure,and can have a variety of shapes, e.g., cage, tube or spherical.

Ion Generation

Various methods may be used for the generation of ions suitable for ionbeams which may be used in treating the cellulosic or lignocellulosicmaterials. After the ions have been generated, they are typicallyaccelerated in one or more of various types of accelerators, and thendirected to impinge on the cellulosic or lignocellulosic materials.

(i) Hydrogen Ions

Hydrogen ions can be generated using a variety of different methods inan ion source. Typically, hydrogen ions are introduced into an ionizingchamber of an ion source, and ions are produced by supplying energy togas molecules. During operation, such chambers can produce large ioncurrents suitable for seeding a downstream ion accelerator.

In some embodiments, hydrogen ions are produced via field ionization ofhydrogen gas. A schematic diagram of a field ionization source is shownin FIG. 7. Field ionization source 1100 includes a chamber 1170 whereionization of gas molecules (e.g., hydrogen gas molecules) occurs. Gasmolecules 1150 enter chamber 1170 by flowing along direction 1155 insupply tube 1120. Field ionization source 1100 includes an ionizationelectrode 1110. During operation, a large potential V_(E) (relative to acommon system ground potential) is applied to electrode 1110. Molecules1150 that circulate within a region adjacent to electrode 1110 areionized by the electric field that results from potential V_(E). Alsoduring operation, an extraction potential V_(X) is applied to extractors1130. The newly-formed ions migrate towards extractors 1130 under theinfluence of the electric fields of potentials V_(E) and V_(X). Ineffect, the newly-formed ions experience repulsive forces relative toionization electrode 1110, and attractive forces relative to extractors1130. As a result, certain of the newly-formed ions enter discharge tube1140, and propagate along direction 1165 under the influence ofpotentials V_(E) and V_(X).

Depending upon the sign of potential V_(E) (relative to the commonground potential), both positively and negatively charged ions can beformed. For example, in some embodiments, a positive potential can beapplied to electrode 1110 and a negative potential can be applied toextractors 1130. Positively charged hydrogen ions (e.g., protons H⁺)that are generated in chamber 1170 are repelled away from electrode 1110and toward extractors 1130. As a result, discharged particle stream 1160includes positively charged hydrogen ions that are transported to aninjector system.

In certain embodiments, a negative potential can be applied to electrode1110 and a positive potential can be applied to extractors 1130.Negatively charged hydrogen ions (e.g., hydride ions H⁻) that aregenerated in chamber 1170 are repelled away from electrode 1110 andtoward extractors 1130. Discharged particle stream 1160 includesnegatively charged hydrogen ions, which are then transported to aninjector system.

In some embodiments, both positive and negative hydrogen ions can beproduced via direct thermal heating of hydrogen gas. For example,hydrogen gas can be directed to enter a heating chamber that isevacuated to remove residual oxygen and other gases. The hydrogen gascan then be heated via a heating element to produce ionic species.Suitable heating elements include, for example, arc dischargeelectrodes, heating filaments, heating coils, and a variety of otherthermal transfer elements.

In certain embodiments, when hydrogen ions are produced via either fieldemission or thermal heating, various hydrogen ion species can beproduced, including both positively and negatively charged ion species,and singly- and multiply-charged ion species. The various ion speciescan be separated from one another via one or more electrostatic and/ormagnetic separators. FIG. 8 shows a schematic diagram of anelectrostatic separator 1175 that is configured to separate a pluralityof hydrogen ion species from one another. Electrostatic separator 1175includes a pair of parallel electrodes 1180 to which a potential Vs isapplied by a voltage source (not shown). Particle stream 1160,propagating in the direction indicated by the arrow, includes a varietyof positively- and negatively-charged, and singly- and multiply-charged,ion species. As the various ion species pass through electrodes 1180,the electric field between the electrodes deflects the ion trajectoriesaccording to the magnitude and sign of the ion species. In FIG. 8, forexample, the electric field points from the lower electrode toward theupper electrode in the region between electrodes 1180. As a result,positively-charged ions are deflected along an upward trajectory in FIG.8, and negatively-charged ions are deflected along a downwardtrajectory. Ion beams 1162 and 1164 each correspond topositively-charged ion species, with the ion species in ion beam 1162having a larger positive charge than the ion species is beam 1164 (e.g.,due to the larger positive charge of the ions in beam 1162, the beam isdeflected to a greater extent).

Similarly, ion beams 1166 and 1168 each correspond to negatively-chargedion species, with the ion species in ion beam 1168 having a largernegative charge than the ion species in ion beam 1166 (and thereby beingdeflected to a larger extent by the electric field between electrodes1180). Beam 1169 includes neutral particles originally present inparticle stream 1160; the neutral particles are largely unaffected bythe electric field between electrodes 1180, and therefore passundeflected through the electrodes. Each of the separated particlestreams enters one of delivery tubes 1192, 1194, 1196, 1198, and 1199,and can be delivered to an injector system for subsequent accelerationof the particles, or steered to be incident directly on the cellulosicor lignocellulosic material. Alternatively, or in addition, any or allof the separated particle streams can be blocked to prevent ion and/oratomic species from reaching cellulosic or lignocellulosic material. Asyet another alternative, certain particle streams can be combined andthen directed to an injector system and/or steered to be incidentdirectly on the cellulosic or lignocellulosic material using knowntechniques.

In general, particle beam separators can also use magnetic fields inaddition to, or rather than, electric fields for deflecting chargedparticles. In some embodiments, particle beam separators includemultiple pairs of electrodes, where each pair of electrodes generates anelectric field that deflects particles passing therethrough.Alternatively, or in addition, particle beam separators can include oneor more magnetic deflectors that are configured to deflect chargedparticles according to magnitude and sign of the particle charges.

(ii) Noble Gas Ions

Noble gas atoms (e.g., helium atoms, neon atoms, argon atoms) formpositively-charged ions when acted upon by relatively strong electricfields. Methods for generating noble gas ions therefore typicallyinclude generating a high-intensity electric field, and then introducingnoble gas atoms into the field region to cause field ionization of thegas atoms. A schematic diagram of a field ionization generator for noblegas ions (and also for other types of ions) is shown in FIG. 9. Fieldionization generator 1200 includes a tapered electrode 1220 positionedwithin a chamber 1210. A vacuum pump 1250 is in fluid communication withthe interior of chamber 1210 via inlet 1240, and reduces the pressure ofbackground gases within chamber 1210 during operation. One or more noblegas atoms 1280 are admitted to chamber 1210 via inlet tube 1230.

During operation, a relatively high positive potential V_(T) (e.g.,positive relative to a common external ground) is applied to taperedelectrode 1220. Noble gas atoms 1280 that enter a region of spacesurrounding the tip of electrode 1220 are ionized by the strong electricfield extending from the tip; the gas atoms lose an electron to the tip,and form positively charged noble gas ions.

The positively charged noble gas ions are accelerated away from the tip,and a certain fraction of the gas ions 1290 pass through extractor 1260and exit chamber 1210, into an ion optical column that includes lens1270, which further deflects and/or focuses the ions.

Electrode 1220 is tapered to increase the magnitude of the localelectric field in the region near the apex of the tip. Depending uponthe sharpness of the taper and the magnitude of potential V_(T), theregion of space in chamber 1210 within which ionization of noble gasatoms occurs can be relatively tightly controlled. As a result, arelatively well collimated beam of noble gas ions 1290 can be obtainedfollowing extractor 1260.

As discussed above in connection with hydrogen ions, the resulting beamof noble gas ions 1290 can be transported through a charged particleoptical column that includes various particle optical elements fordeflecting and/or focusing the noble gas ion beam. The noble gas ionbeam can also pass through an electrostatic and/or magnetic separator,as discussed above in connection with FIG. 8.

Noble gas ions that can be produced in field ionization generator 1200include helium ions, neon ions, argon ions, and krypton ions. Inaddition, field ionization generator 1200 can be used to generate ionsof other gaseous chemical species, including hydrogen, nitrogen, andoxygen.

Noble gas ions may have particular advantages relative to other ionspecies when treating cellulosic or lignocellulosic material. Forexample, while noble gas ions can react with cellulosic orlignocellulosic materials, neutralized noble gas ions (e.g., noble gasatoms) that are produced from such reactions are generally inert, and donot further react with the cellulosic or lignocellulosic material.Moreover, neutral noble gas atoms do not remain embedded in thecellulosic or lignocellulosic material, but instead diffuse out of thematerial. Noble gases are non-toxic and can be used in large quantitieswithout adverse consequences to either human health or the environment.

(iii) Carbon, Oxygen, and Nitrogen Ions

Ions of carbon, oxygen, and nitrogen can typically be produced by fieldionization in a system such as field ionization source 1100 or fieldionization generator 1200. For example, oxygen gas molecules and/oroxygen atoms (e.g., produced by heating oxygen gas) can be introducedinto a chamber, where the oxygen molecules and/or atoms are fieldionized to produce oxygen ions. Depending upon the sign of the potentialapplied to the field ionization electrode, positively- and/ornegatively-charged oxygen ions can be produced. The desired ion speciescan be preferentially selected from among various ion species andneutral atoms and molecules by an electrostatic and/or magnetic particleselector, as shown in FIG. 8.

As another example, nitrogen gas molecules can be introduced into thechamber of either field ionization source 1100 or field ionizationgenerator 1200, and ionized to form positively- and/ornegatively-charged nitrogen ions by the relatively strong electric fieldwithin the chamber. The desired ion species can then be separated fromother ionic and neutral species via an electrostatic and/or magneticseparator, as shown in FIG. 8.

To form carbon ions, carbon atoms can be supplied to the chamber ofeither field ionization source 1100 or field ionization generator 1200,wherein the carbon atoms can be ionized to form either positively-and/or negatively-charged carbon ions. The desired ion species can thenbe separated from other ionic and neutral species via an electrostaticand/or magnetic separator, as shown in FIG. 8. The carbon atoms that aresupplied to the chamber of either field ionization source 1100 or fieldionization generator 1200 can be produced by heating a carbon-basedtarget (e.g., a graphite target) to cause thermal emission of carbonatoms from the target. The target can be placed in relatively closeproximity to the chamber, so that emitted carbon atoms enter the chamberdirectly following emission.

(iv) Heavier Ions

Ions of heavier atoms such as sodium and iron can be produced via anumber of methods. For example, in some embodiments, heavy ions such assodium and/or iron ions are produced via thermionic emission from atarget material that includes sodium and/or iron, respectively. Suitabletarget materials include materials such as sodium silicates and/or ironsilicates. The target materials typically include other inert materialssuch as beta-alumina. Some target materials are zeolite materials, andinclude channels formed therein to permit escape of ions from the targetmaterial.

FIG. 10 shows a thermionic emission source 1300 that includes a heatingelement 1310 that contacts a target material 1330, both of which arepositioned inside an evacuated chamber 1305. Heating element 1310 iscontrolled by controller 1320, which regulates the temperature ofheating element 1310 to control the ion current generated from targetmaterial 1330. When sufficient heat is supplied to target material 1330,thermionic emission from the target material generates a stream of ions1340. Ions 1340 can include positively-charged ions of materials such assodium, iron, and other relatively heavy atomic species (e.g., othermetal ions). Ions 1340 can then be collimated, focused, and/or otherwisedeflected by electrostatic and/or magnetic electrodes 1350, which canalso deliver ions 1340 to an injector.

Thermionic emission to form ions of relatively heavy atomic species isalso discussed, for example, in U.S. Pat. No. 4,928,033, entitled“Thermionic Ionization Source,” the entire contents of which areincorporated herein by reference.

In certain embodiments, relatively heavy ions such as sodium ions and/oriron ions can be produced by microwave discharge. FIG. 11 shows aschematic diagram of a microwave discharge source 1400 that producesions from relatively heavy atoms such as sodium and iron. Dischargesource 1400 includes a microwave field generator 1410, a waveguide tube1420, a field concentrator 1430, and an ionization chamber 1490. Duringoperation, field generator 1410 produces a microwave field whichpropagates through waveguide 1420 and concentrator 1430; concentrator1430 increases the field strength by spatially confining the field, asshown in FIG. 11. The microwave field enters ionization chamber 1490. Ina first region inside chamber 1490, a solenoid 1470 produces a strongmagnetic field 1480 in a region of space that also includes themicrowave field. Source 1440 delivers atoms 1450 to this region ofspace. The concentrated microwave field ionizes atoms 1450, and themagnetic field 1480 generated by solenoid 1470 confines the ionizedatoms to form a localized plasma. A portion of the plasma exits chamber1490 as ions 1460. Ions 1460 can then be deflected and/or focused by oneor more electrostatic and/or magnetic elements, and delivered to aninjector.

Atoms 1450 of materials such as sodium and/or iron can be generated bythermal emission from a target material, for example. Suitable targetmaterials include materials such as silicates and other stable salts,including zeolite-based materials. Suitable target materials can alsoinclude metals (e.g., iron), which can be coated on an inert basematerial such as a glass material.

Microwave discharge sources are also discussed, for example, in thefollowing U.S. patents: U.S. Pat. No. 4,409,520, entitled “MicrowaveDischarge Ion Source,” and U.S. Pat. No. 6,396,211, entitled “MicrowaveDischarge Type Electrostatic Accelerator Having Upstream and DownstreamAcceleration Electrodes.” The entire contents of each of the foregoingpatents are incorporated herein by reference.

Particle Beam Sources

Particle beam sources that generate beams for use in irradiatingcellulosic or lignocellulosic material typically include three componentgroups: an injector, which generates or receives ions and introduces theions into an accelerator; an accelerator, which receives ions from theinjector and increases the kinetic energy of the ions; and outputcoupling elements, which manipulate the beam of accelerated ions.

(i) Injectors

Injectors can include, for example, any of the ion sources discussed inthe preceding sections above, which supply a stream of ions forsubsequent acceleration. Injectors can also include various types ofelectrostatic and/or magnetic particle optical elements, includinglenses, deflectors, collimators, filters, and other such elements. Theseelements can be used to condition the ion beam prior to entering theaccelerator; that is, these elements can be used to control thepropagation characteristics of the ions that enter the accelerator.Injectors can also include pre-accelerating electrostatic and/ormagnetic elements that accelerate charged particles to a selected energythreshold prior to entering the accelerator. An example of an injectoris shown in Iwata, Y. et al.

(ii) Accelerators

One type of accelerator that can be used to accelerate ions producedusing the sources discussed above is a Dynamitron® (available, forexample, from Radiation Dynamics Inc., now a unit of IBA,Louvain-la-Neuve, Belgium). A schematic diagram of a Dynamitron®accelerator 1500 is shown in FIG. 6 and discussed above.

Another type of accelerator that can be used to accelerate ions fortreatment of cellulosic or lignocellulosic-based material is aRhodotron® accelerator (available, for example, from IBA,Louvain-la-Neuve, Belgium). In general, Rhodotron-type acceleratorsinclude a single recirculating cavity through which ions that are beingaccelerated make multiple passes. As a result, Rhodotron® acceleratorscan be operated in continuous mode at relatively high continuous ioncurrents.

FIG. 12 shows a schematic diagram of a Rhodotron® accelerator 1700.Accelerator 1700 includes an injector 1710, which introduces acceleratedions into recirculating cavity 1720. An electric field source 1730 ispositioned within an inner chamber 1740 of cavity 1720, and generates anoscillating radial electric field. The oscillation frequency of theradial field is selected to match the transit time of injected ionsacross one pass of recirculating cavity 1720. For example, apositively-charged ion is injected into cavity 1720 by injector 1710when the radial electric field in the cavity has zero amplitude. As theion propagates toward chamber 1740, the amplitude of the radial field inchamber 1740 increases to a maximum value, and then decreases again. Theradial field points inward toward chamber 1740, and the ion isaccelerated by the radial field. The ion passes through a hole in thewall of inner chamber 1740, crosses the geometrical center of cavity1720, and passes out through another hole in the wall of inner chamber1740. When the ion is positioned at the enter of cavity 1720, theelectric field amplitude inside cavity 1720 has been reduced to zero (ornearly zero). As the ion emerges from inner chamber 1740, the electricfield amplitude in cavity 1720 begins to increase again, but the fieldis now oriented radially outward. The field magnitude during the secondhalf of the ion's pass through cavity 1720 again reaches a maximum andthen begins to diminish. As a result, the positive ion is againaccelerated by the electric field as the ion completes the second halfof a first pass through cavity 1720.

Upon reaching the wall of cavity 1720, the magnitude of the electricfield in cavity 1720 is zero (or nearly zero) and the ion passes throughan aperture in the wall and encounters one of beam deflection magnets1750. The beam deflection magnets essentially reverse the trajectory ofthe ion, as shown in FIG. 12, directing the ion to re-enter cavity 1720through another aperture in the wall of the chamber. When the ionre-enters cavity 1720, the electric field therein begins to increase inamplitude again, but is now once more oriented radially inward. Thesecond and subsequent passes of the ion through cavity 1720 follow asimilar pattern, so that the orientation of the electric field alwaysmatches the direction of motion of the ion, and the ion is acceleratedon every pass (and every half-pass) through cavity 1720.

As shown in FIG. 12, after six passes through cavity 1720, theaccelerated ion is coupled out of cavity 1720 as a portion ofaccelerated ion beam 1760. The accelerated ion beam passes through oneor more electrostatic and/or magnetic particle optical elements 1770,which can include lenses, collimators, beam deflectors, filters, andother optical elements. For example, under control of an external logicunit, elements 1770 can include an electrostatic and/or magneticdeflector that sweeps accelerated beam 1760 across a two-dimensionalplanar region oriented perpendicular to the direction of propagation ofbeam 1760.

Ions that are injected into cavity 1720 are accelerated on each passthrough cavity 1720. In general, therefore, to obtain accelerated beamshaving different average ion energies, accelerator 1700 can include morethan one output coupling. For example, in some embodiments, one or moreof deflection magnets 1750 can be modified to allow a portion of theions reaching the magnets to be coupled out of accelerator 1700, and aportion of the ions to be returned to chamber 1720. Multiple acceleratedoutput beams can therefore be obtained from accelerator 1700, each beamcorresponding to an average ion energy that is related to the number ofpasses through cavity 1720 for the ions in the beam.

Accelerator 1700 includes 5 deflection magnets 1750, and ions injectedinto cavity 1720 make 6 passes through the cavity. In general, however,accelerator 1700 can include any number of deflection magnets, and ionsinjected into cavity 1720 can make any corresponding number of passesthrough the cavity. For example, in some embodiments, accelerator 1700can include at least 6 deflection magnets and ions can make at least 7passes through the cavity (e.g., at least 7 deflection magnets and 8passes through the cavity, at least 8 deflection magnets and 9 passesthrough the cavity, at least 9 deflection magnets and 10 passes throughthe cavity, at least 10 deflection magnets and 11 passes through thecavity).

Typically, the electric field generated by field source 1730 provides asingle-cavity-pass gain of about 1 MeV to an injected ion. In general,however, higher single-pass gains are possible by providing ahigher-amplitude electric field within cavity 1720. In some embodiments,for example, the single-cavity-pass gain is about 1.2 MeV or more (e.g.,1.3 MeV or more, 1.4 MeV or more, 1.5 MeV or more, 1.6 MeV or more, 1.8MeV or more, 2.0 MeV or more, 2.5 MeV or more).

The single-cavity-pass gain also depends upon the magnitude of thecharge carried by the injected ion. For example, ions bearing multiplecharges will experience higher single-pass-cavity gain than ions bearingsingle charges, for the same electric field within cavity. As a result,the single-pass-cavity gain of accelerator 1700 can be further increasedby injecting ions having multiple charges.

In the foregoing description of accelerator 1700, a positively-chargedion was injected into cavity 1720. Accelerator 1700 can also acceleratenegatively charged ions. To do so, the negatively charged ions areinjected so that the direction of their trajectories is out of phasewith the radial electric field direction. That is, the negativelycharged ions are injected so that on each half pass through cavity 1720,the direction of the trajectory of each ion is opposite to the directionof the radial electric field. Achieving this involves simply adjustingthe time at which negatively-charged ions are injected into cavity 1720.Accordingly, accelerator 1700 is capable of simultaneously acceleratingions having the same approximate mass, but opposite charges. Moregenerally, accelerator 1700 is capable of simultaneously acceleratingdifferent types of both positively- and negatively-charged (and bothsingly- and multiply-charged) ions, provided that the transit times ofthe ions across cavity 1720 are relatively similar. In some embodiments,accelerator 1700 can include multiple output couplings, providingdifferent types of accelerated ion beams having similar or differentenergies.

Other types of accelerators can also be used to accelerate ions forirradiation of cellulosic or lignocellulosic material. For example, insome embodiments, ions can be accelerated to relatively high averageenergies in cyclotron- and/or synchrotron-based accelerators. Theconstruction and operation of such accelerators is well-known in theart. As another example, in some embodiments, Penning-type ion sourcescan be used to generate and/or accelerate ions for treating cellulosicor lignocellulosic-based material. The design of Penning-type sources isdiscussed in section 7.2.1 of Prelec (1997).

Static and/or dynamic accelerators of various types can also generallybe used to accelerate ions. Static accelerators typically include aplurality of electrostatic lenses that are maintained at different DCvoltages. By selecting appropriate values of the voltages applied toeach of the lens elements, ions introduced into the accelerator can beaccelerated to a selected final energy. FIG. 13 shows a simplifiedschematic diagram of a static accelerator 1800 that is configured toaccelerate ions to treat cellulosic or lignocellulosic material 1835.Accelerator 1800 includes an ion source 1810 that produces ions andintroduces the ions into an ion column 1820. Ion column 1820 includes aplurality of electrostatic lenses 1825 that accelerate the ionsgenerated by ion source 1810 to produce an ion beam 1815. DC voltagesare applied to lenses 1825; the potentials of the lenses remainapproximately constant during operation. Generally, the electricalpotential within each lens is constant, and the ions of ion beam 1815are accelerated in the gaps between the various lenses 1825. Ion column1820 also includes a deflection lens 1830 and a collimation lens 1832.These two lenses operate to direct ion beam 1815 to a selected positionon cellulosic or lignocellulosic material 1835, and to focus ion beam1815 onto the cellulosic or lignocellulosic material.

Although FIG. 13 shows a particular embodiment of a static accelerator,many other variations are possible and suitable for treating cellulosicor lignocellulosic material. In some embodiments, for example, therelative positions of deflection lens 1830 and collimation lens 1832along ion column 1820 can be exchanged. Additional electrostatic lensescan also be present in ion column 1820, and ion column 1820 can furtherinclude magnetostatic optical elements. In certain embodiments, a widevariety of additional elements can be present in ion column 1820,including deflectors (e.g., quadrupole, hexapole, and/or octopoledeflectors), filtering elements such as apertures to remove undesiredspecies (e.g., neutrals and/or certain ionic species) from ion beam1815, extractors (e.g., to establish a spatial profile for ion beam1815), and other electrostatic and/or magnetostatic elements.

Dynamic linear accelerators—often referred to as LINACS—can also be usedto generate an ion beam that can be used to treat cellulosic orlignocellulosic material. Typically, dynamic linear accelerators includean ion column with a linear series of radiofrequency cavities, each ofwhich produces an intense, oscillating radiofrequency (RF) field that istimed to coincide with injection and propagation of ions into the ioncolumn. As an example, devices such as klystrons can be used togenerated the RF fields in the cavities. By matching the fieldoscillations to the injection times of ions, the RF cavities canaccelerate ions to high energies without having to maintain peakpotentials for long periods of time. As a result, LINACS typically donot have the same shielding requirements as DC accelerators, and aretypically shorter in length. LINACS typically operate at frequencies of3 GHz (S-band, typically limited to relatively low power) and 1 GHz(L-band, capable of significantly higher power operation). TypicalLINACS have an overall length of 2-4 meters.

A schematic diagram of a dynamic linear accelerator 1850 (e.g., a LINAC)is shown in FIG. 14. LINAC 1850 includes an ion source 1810 and an ioncolumn 1855 that includes three acceleration cavities 1860, a deflector1865, and a focusing lens 1870. Deflector 1865 and focusing lens 1870function to steer and focus ion beam 1815 onto cellulosic orlignocellulosic material 1835 following acceleration, as discussedabove. Acceleration cavities 1860 are formed of a conductive materialsuch as copper, and function as a waveguide for the accelerated ions.Klystrons 1862, connected to each of cavities 1860, generate the dynamicRF fields that accelerate the ions within the cavities. Klystrons 1862are individually configured to produce RF fields that, together,accelerate the ions in ion beam 1815 to a final, selected energy priorto being incident on cellulosic or lignocellulosic material 1835.

As discussed above in connection with static accelerators, manyvariations of dynamic accelerator 1850 are possible and can be used toproduce an ion beam for treating cellulosic or lignocellulosic material.For example, in some embodiments, additional electrostatic lenses canalso be present in ion column 1855, and ion column 1855 can furtherinclude magnetostatic optical elements. In certain embodiments, a widevariety of additional elements can be present in ion column 1855,including deflectors (e.g., quadrupole, hexapole, and/or octopoledeflectors), filtering elements such as apertures to remove undesiredspecies (e.g., neutrals and/or certain ionic species) from ion beam1815, extractors (e.g., to establish a spatial profile for ion beam1815), and other electrostatic and/or magnetostatic elements. Inaddition to the specific static and dynamic accelerators discussedabove, other suitable accelerator systems include, for example: DCinsulated core transformer (ICT) type systems, available from NissinHigh Voltage, Japan; S-band LINACS, available from L3-PSD (USA), LinacSystems (France), Mevex (Canada), and Mitsubishi Heavy Industries(Japan); L-band LINACS, available from Iotron Industries (Canada); andILU-based accelerators, available from Budker Laboratories (Russia).

In some embodiments, van de Graaff-based accelerators can be used toproduce and/or accelerate ions for subsequent treatment of cellulosic orlignocellulosic material. FIG. 15 shows an embodiment of a van de Graaffaccelerator 1900 that includes a spherical shell electrode 1902 and aninsulating belt 1906 that recirculates between electrode 1902 and a base1904 of accelerator 1900. During operation, insulating belt 1906 travelsover pulleys 1910 and 1908 in the direction shown by arrow 1918, andcarries charge into electrode 1902. Charge is removed from belt 1906 andtransferred to electrode 1902, so that the magnitude of the electricalpotential on electrode 1902 increases until electrode 1902 is dischargedby a spark (or, alternatively, until the charging current is balanced bya load current).

Pulley 1910 is grounded, as shown in FIG. 15. A corona discharge ismaintained between a series of points or a fine wire on one side of belt1906. Wire 1914 is configured to maintain the corona discharge inaccelerator 1900. Wire 1914 is maintained at a positive potential, sothat belt 1906 intercepts positive ions moving from wire 1914 to pulley1910. As belt 1906 moves in the direction of arrow 1918, the interceptedcharges are carried into electrode 1902, where they are removed frombelt 1906 by a needle point 1916 and transferred to electrode 1902. As aresult, positive charges accumulate on the surface of electrode 1902;these charges can be discharged from the surface of electrode 1902 andused to treat cellulosic or lignocellulosic material. In someembodiments, accelerator 1900 can be configured to provide negativelycharged ions by operating wire 1914 and needle point 1916 at a negativepotential with respect to grounded pulley 1910.

In general, accelerator 1900 can be configured to provide a wide varietyof different types of positive and negative charges for treatingcellulosic or lignocellulosic material. Exemplary types of chargesinclude electrons, protons, hydrogen ions, carbon ions, oxygen ions,halogen ions, metal ions, and other types of ions.

In certain embodiments, tandem accelerators (including folded tandemaccelerators) can be used to generate ion beams for treatment ofcellulosic or lignocellulosic material. An example of a folded tandemaccelerator 1950 is shown in FIG. 16. Accelerator 1950 includes anaccelerating column 1954, a charge stripper 1956, a beam deflector 1958,and an ion source 1952.

During operation, ion source 1952 produces a beam 1960 of negativelycharged ions, which is directed to enter accelerator 1950 through inputport 1964. In general, ion source 1952 can be any type of ion sourcethat produces negatively charged ions. For example, suitable ion sourcesinclude a source of negative ions by cesium sputtering (SNICS) source, aRF-charge exchange ion source, or a toroidal volume ion source (TORVIS).Each of the foregoing exemplary ion sources is available, for example,from National Electrostatics Corporation (Middleton, Wis.).

Once inside accelerator 1950, the negative ions in beam 1960 areaccelerated by accelerating column 1954. Typically, accelerating column1954 includes a plurality of accelerating elements such as electrostaticlenses. The potential difference applied in column 1954 to acceleratethe negative ions can be generated using various types of devices. Forexample, in some embodiments, (e.g., Pelletron® accelerators), thepotential is generated using a Pelletron® charging device. Pelletron®devices include a charge-carrying belt that is formed from a pluralityof metal (e.g., steel) chain links or pellets that are bridged byinsulating connectors (e.g., formed from a material such as nylon).During operation, the belt recirculates between a pair of pulleys, oneof which is maintained at ground potential. As the belt moves betweenthe grounded pulley and the opposite pulley (e.g., the terminal pulley),the metal pellets are positively charged by induction. Upon reaching theterminal pulley, the positive charge that has accumulated on the belt isremoved, and the pellets are negatively charged as they leave theterminal pulley and return to the ground pulley.

The Pelletron® device generates a large positive potential within column1954 that is used to accelerate the negative ions of beam 1960. Afterundergoing acceleration in column 1954, beam 1960 passes through chargestripper 1956. Charge stripper 1956 can be implemented as a thin metalfoil and/or a tube containing a gas that strips electrons from thenegative ions, for example. The negatively charged ions are therebyconverted to positively charged ions, which emerge from charge stripper1956. The trajectories of the emerging positively charged ions arealtered so that the positively charged ions travel back throughaccelerating column 1954, undergoing a second acceleration in the columnbefore emerging as positively charged ion beam 1962 from output port1966. Positively charged ion beam 1962 can then be used to treatcellulosic or lignocellulosic material according to the various methodsdisclosed herein.

Due to the folded geometry of accelerator 1950, ions are accelerated toa kinetic energy that corresponds to twice the potential differencegenerated by the Pelletron® charging device. For example, in a 2 MVPelletron® accelerator, hydride ions that are introduced by ion source1952 will be accelerated to an intermediate energy of 2 MeV during thefirst pass through column 1954, converted to positive ions (e.g.,protons), and accelerated to a final energy of 4 MeV during the secondpass through column 1954.

In certain embodiments, column 1954 can include elements in addition to,or as alternatives to, the Pelletron® charging device. For example,column 1954 can include static accelerating elements (e.g., DCelectrodes) and/or dynamic acceleration cavities (e.g., LINAC-typecavities with pulse RF field generators for particle acceleration).Potentials applied to the various accelerating devices are selected toaccelerate the negatively charged ions of beam 1960.

Exemplary tandem accelerators, including both folded and non-foldedaccelerators, are available from National Electrostatics Corporation(Middleton, Wis.), for example.

In some embodiments, combinations of two or more of the various types ofaccelerators can be used to produce ion beams that are suitable fortreating cellulosic or lignocellulosic material. For example, a foldedtandem accelerator can be used in combination with a linear accelerator,a Rhodotron® accelerator, a Dynamitron®, a static accelerator, or anyother type of accelerator to produce ion beams. Accelerators can be usedin series, with the output ion beam from one type of acceleratordirected to enter another type of accelerator for additionalacceleration. Alternatively, multiple accelerators can be used inparallel to generate multiple ion beams. In certain embodiments,multiple accelerators of the same type can be used in parallel and/or inseries to generate accelerated ion beams.

In some embodiments, multiple similar and/or different accelerators canbe used to generate ion beams having different compositions. Forexample, a first accelerator can be used to generate one type of ionbeam, while a second accelerator can be used to generate a second typeof ion beam. The two ion beams can then each be further accelerated inanother accelerator, or can be used to treat cellulosic orlignocellulosic material.

Further, in certain embodiments, a single accelerator can be used togenerate multiple ion beams for treating cellulosic or lignocellulosicmaterial. For example, any of the accelerators discussed herein (andother types of accelerators as well) can be modified to produce multipleoutput ion beams by sub-dividing an initial ion current introduced intothe accelerator from an ion source. Alternatively, or in addition, anyone ion beam produced by any of the accelerators disclosed herein caninclude only a single type of ion, or multiple different types of ions.

In general, where multiple different accelerators are used to produceone or more ion beams for treatment of cellulosic or lignocellulosicmaterial, the multiple different accelerators can be positioned in anyorder with respect to one another. This provides for great flexibilityin producing one or more ion beams, each of which has carefully selectedproperties for treating cellulosic or lignocellulosic material (e.g.,for treating different components in cellulosic or lignocellulosicmaterial).

The ion accelerators disclosed herein can also be used in combinationwith any of the other treatment steps disclosed herein. For example, insome embodiments, electrons and ions can be used in combination to treatcellulosic or lignocellulosic material. The electrons and ions can beproduced and/or accelerated separately, and used to treat cellulosic orlignocellulosic material sequentially (in any order) and/orsimultaneously. In certain embodiments, electron and ion beams can beproduced in a common accelerator and used to treat cellulosic orlignocellulosic material. For example, many of the ion acceleratorsdisclosed herein can be configured to produce electron beams as analternative to, or in addition to, ion beams. For example, Dynamitron®accelerators, Rhodotron® accelerators, and LINACs can be configured toproduce electron beams for treatment of cellulosic or lignocellulosicmaterial.

Moreover, treatment of cellulosic or lignocellulosic material with ionbeams can be combined with other techniques such as sonication. Ingeneral, sonication-based treatment can occur before, during, or afterion-based treatment. Other treatments such as electron beam treatmentcan also occur in any combination and/or order with ultrasonic treatmentand ion beam treatment.

Process Water

In the processes disclosed herein, whenever water is used in anyprocess, it may be grey water, e.g., municipal grey water, or blackwater. In some embodiments, the grey or black water is sterilized priorto use. Sterilization may be accomplished by any desired technique, forexample by irradiation, steam, or chemical sterilization.

EXAMPLES

The following examples are not limiting to the inventions claimedherein.

Example 1—Methods of Determining Molecular Weight of Cellulosic andLignocellulosic Materials by Gel Permeation Chromatography

This example illustrates how molecular weight is determined for thematerials discussed herein. Cellulosic and lignocellulosic materials foranalysis were treated as follows:

A 1500 pound skid of virgin bleached white Kraft board having a bulkdensity of 30 lb/ft³ was obtained from International Paper. The materialwas folded flat, and then fed into a 3 hp Flinch Baugh shredder at arate of approximately 15 to 20 pounds per hour. The shredder wasequipped with two 12 inch rotary blades, two fixed blades and a 0.30inch discharge screen. The gap between the rotary and fixed blades wasadjusted to 0.10 inch. The output from the shredder resembled confetti(as above). The confetti-like material was fed to a Munson rotary knifecutter, Model SC30. The discharge screen had ⅛ inch openings. The gapbetween the rotary and fixed blades was set to approximately 0.020 inch.The rotary knife cutter sheared the confetti-like pieces across theknife-edges. The material resulting from the first shearing was fed backinto the same setup and the screen was replaced with a 1/16 inch screen.This material was sheared. The material resulting from the secondshearing was fed back into the same setup and the screen was replacedwith a 1/32 inch screen. This material was sheared. The resultingfibrous material had a BET surface area of 1.6897 m²/g+/−0.0155 m²/g, aporosity of 87.7163 percent and a bulk density (@0.53 psia) of 0.1448g/mL. An average length of the fibers was 0.824 mm and an average widthof the fibers was 0.0262 mm, giving an average L/D of 32:1.

Sample materials presented in the following Tables 1 and 2 include Kraftpaper (P), wheat straw (WS), alfalfa (A), and switchgrass (SG). Thenumber “132” of the Sample ID refers to the particle size of thematerial after shearing through a 1/32 inch screen. The number after thedash refers to the dosage of radiation (MRad) and “US” refers toultrasonic treatment. For example, a sample ID “P132-10” refers to Kraftpaper that has been sheared to a particle size of 132 mesh and has beenirradiated with 10 MRad.

TABLE 1 Peak Average Molecular Weight of Irradiated Kraft Paper SampleSample Dosage¹ Average MW ± Source ID (MRad) Ultrasound² Std Dev. KraftP132 0 No 32853 ± 10006 Paper P132-10 10 ″  61398 ± 2468** P132-100 100″ 8444 ± 580  P132-181 181 ″ 6668 ± 77  P132-US 0 Yes 3095 ± 1013 **Lowdoses of radiation appear to increase the molecular weight of somematerials ¹Dosage Rate = 1 MRad/hour ²Treatment for 30 minutes with 20kHz ultrasound using a 1000 W horn under re-circulating conditions withthe material dispersed in water.

TABLE 2 Peak Average Molecular Weight of Irradiated Materials Dosage¹Average MW ± Sample ID Peak # (MRad) Ultrasound² Std Dev. WS132 1  0 No1407411 ± 175191 2 ″ ″ 39145 ± 3425 3 ″ ″ 2886 ± 177 WS132-10* 1 10 ″26040 ± 3240 WS132-100* 1 100  ″ 23620 ± 453  A132 1  0 ″ 1604886 ±151701 2 ″ ″ 37525 ± 3751 3 ″ ″ 2853 ± 490 A132-10* 1 10 ″ 50853 ± 16652 ″ ″ 2461 ± 17  A132-100* 1 100  ″ 38291 ± 2235 2 ″ ″ 2487 ± 15  SG1321  0 ″ 1557360 ± 83693  2 ″ ″ 42594 ± 4414 3 ″ ″ 3268 ± 249 SG132-10* 110 ″ 60888 ± 9131 SG132-100* 1 100  ″ 22345 ± 3797 SG132-10-US 1 10 Yes 86086 ± 43518 2 ″ ″ 2247 ± 468 SG132-100-US 1 100  ″  4696 ± 1465*Peaks coalesce after treatment **Low doses of radiation appear toincrease the molecular weight of some materials ¹Dosage Rate = 1MRad/hour ²Treatment for 30 minutes with 20 kHz ultrasound using a 1000W horn under re-circulating conditions with the material dispersed inwater.

Gel Permeation Chromatography (GPC) is used to determine the molecularweight distribution of polymers. During GPC analysis, a solution of thepolymer sample is passed through a column packed with a porous geltrapping small molecules. The sample is separated based on molecularsize with larger molecules eluting sooner than smaller molecules. Theretention time of each component is most often detected by refractiveindex (RI), evaporative light scattering (ELS), or ultraviolet (UV) andcompared to a calibration curve. The resulting data is then used tocalculate the molecular weight distribution for the sample.

A distribution of molecular weights rather than a unique molecularweight is used to characterize synthetic polymers. To characterize thisdistribution, statistical averages are utilized. The most common ofthese averages are the “number average molecular weight” (M_(n)) and the“weight average molecular weight” (M_(w)). Methods of calculating thesevalues are described in the art, e.g., in Example 9 of WO 2008/073186.

M_(n) is similar to the standard arithmetic mean associated with a groupof numbers. When applied to polymers, M_(n) refers to the averagemolecular weight of the molecules in the polymer. M_(n) is calculatedaffording the same amount of significance to each molecule regardless ofits individual molecular weight. The average M_(n) is calculated by thefollowing formula where N_(i) is the number of molecules with a molarmass equal to M_(i).

${\overset{\_}{M}}_{n} = \frac{\sum\limits_{i}{N_{i}M_{i}}}{\sum\limits_{i}N_{i}}$

M_(w) is another statistical descriptor of the molecular weightdistribution that places a greater emphasis on larger molecules thansmaller molecules in the distribution. The formula below shows thestatistical calculation of the weight average molecular weight.

${\overset{\_}{M}}_{w} = \frac{\sum\limits_{i}{N_{i}M_{i}^{2}}}{\sum\limits_{i}{N_{i}M_{i}}}$

The polydispersity index or PI is defined as the ratio of M_(w)/M_(n).The larger the PI, the broader or more disperse the distribution. Thelowest value that a PI can be is 1. This represents a monodispersesample; that is, a polymer with all of the molecules in the distributionbeing the same molecular weight.

The peak molecular weight value (M_(P)) is another descriptor defined asthe mode of the molecular weight distribution. It signifies themolecular weight that is most abundant in the distribution. This valuealso gives insight to the molecular weight distribution.

Most GPC measurements are made relative to a different polymer standard.The accuracy of the results depends on how closely the characteristicsof the polymer being analyzed match those of the standard used. Theexpected error in reproducibility between different series ofdeterminations, calibrated separately, is ca. 5-10% and ischaracteristic to the limited precision of GPC determinations.Therefore, GPC results are most useful when a comparison between themolecular weight distribution of different samples is made during thesame series of determinations.

The lignocellulosic samples required sample preparation prior to GPCanalysis. First, a saturated solution (8.4% by weight) of lithiumchloride (LiCl) was prepared in dimethyl acetamide (DMAc). Approximately100 mg of each sample was added to approximately 10 g of a freshlyprepared saturated LiCl/DMAc solution, and the mixture was heated toapproximately 150° C.-170° C. with stirring for 1 hour. The resultingsolutions were generally light- to dark-yellow in color. The temperatureof the solutions was decreased to approximately 100° C. and thesolutions were heated for an additional 2 hours. The temperature of thesolutions was then decreased to approximately 50° C. and the samplesolutions were heated for approximately 48 to 60 hours. Of note, samplesirradiated at 100 MRad were more easily solubilized as compared to theiruntreated counterpart. Additionally, the sheared samples (denoted by thenumber 132) had slightly lower average molecular weights as comparedwith uncut samples.

The resulting sample solutions were diluted 1:1 using DMAc as solventand were filtered through a 0.45 μm PTFE filter. The filtered samplesolutions were then analyzed by GPC. The peak average molecular weights(Mp) of the samples, as determined by Gel Permeation Chromatography(GPC), are summarized in Tables 1 and 2. Each sample was prepared induplicate and each preparation of the sample was analyzed in duplicate(two injections) for a total of four injections per sample. The EasiCal®polystyrene standards PS1A and PS1B were used to generate a calibrationcurve for the molecular weight scale from about 580 to 7,500,00 Daltons.The GPC analysis conditions are recited in Table 3 below.

TABLE 3 GPC Analysis Conditions Instrument: Waters Alliance GPC 2000Plgel 10μ Mixed-B Columns (3): S/N’s: 10M-MB-148-83; 10M-MB-148-84;10M-MB-174-129 Mobile Phase 0.5% LiCl in DMAc (1.0 mL/min.) (solvent):Column/Detector 70° C. Temperature: Injector Temperature: 70° C. SampleLoop Size: 323.5 μL

Example 2—Electron Beam Processing Textile Samples

Cellulosic yarn samples are treated with a beam of electrons using avaulted Rhodotron® TT200 continuous wave accelerator delivering 5 MeVelectrons at 80 kW output power. Table 4 describes the nominalparameters for the TT200. Table 5 describes the nominal doses (in MRad)and actual doses (in kgy) that are delivered to the samples.

TABLE 4 Rhodotron ® TT 200 Parameters Beam Beam Produced: Acceleratedelectrons Beam energy: Nominal (maximum): 10 MeV (+0 keV-250 keV Energydispersion at 10 Mev: Full width half maximum (FWHM) 300 keV Beam powerat 10 MeV: Guaranteed Operating Range 1 to 80 kW Power ConsumptionStand-by condition <15 kW (vacuum and cooling ON): At 50 kW beam power:<210 kW At 80 kW beam power: <260 kW RF System Frequency: 107.5 ± 1 MHzTetrode type: Thomson TH781 Scanning Horn Nominal Scanning Length(measured at 25-35 120 cm cm from window): Scanning Range: From 30% to100% of Nominal Scanning Length Nominal Scanning Frequency (at max. 100Hz ± 5% Scanning length): Scanning Uniformity (across 90% of Nominal ±5%Scanning Length)

TABLE 5 Dosages Delivered to Samples Total Dosage (MRad) (NumberAssociated with Sample ID Delivered Dose (kgy)¹ 0.1 0.99 1 9.9 3 29.0 550.4 7 69.2 ¹For example, 9.9 kgy is delivered in 11 seconds at a beamcurrent of 5 mA and a line speed of 12.9 feet/minute. Cool time between1 MRad treatments is about 2 minutes.

OTHER EMBODIMENTS

It is to be understood that while the invention has been described inconjunction with the detailed description thereof, the foregoingdescription is intended to illustrate and not limit the scope of theinvention, which is defined by the scope of the appended claims.

For example, in some embodiments a high dose of very low energyradiation may be applied to a textile having a sizing or other coatingthat is to be removed. The penetration depth of the radiation isselected so that only the coating is irradiated. The dose is selected sothat the radiation will partly or fully break down the coating, e.g., toallow the coating to be rinsed off of or otherwise removed from thetextile. Electron beam radiation is generally preferred for thisprocess, as penetration depth can be readily and accurately controlled.Suitable equipment for performing this method is commercially available,e.g., the Compact High Voltage Systems available from Energy Sciences,Inc.

Other aspects, advantages, and modifications are within the scope of thefollowing claims.

What is claimed is:
 1. A method of manufacturing a garment, the methodcomprising: exposing a garment body formed from a textile comprising acellulosic or lignocellulosic material to a particle beam of sufficientenergy to penetrate and thereby irradiate the textile.
 2. The method ofclaim 1 wherein the particle beam irradiates the textile with a dose ofionizing radiation that is sufficient to increase the molecular weightof the cellulosic or lignocellulosic material.
 3. The method of claim 2,wherein the dose of ionizing radiation is at from about 0.25 to about2.5 MRad,
 4. The method of claim 1 wherein the particle beam is anelectron beam.
 5. The method of claim 4 wherein electrons in theelectron beam have an energy of at least 0.25 MeV.
 6. The method ofclaim 5 wherein the electrons have an energy between 0.25 MeV and 7.5MeV.
 7. The method of claim 1, wherein the fibrous cellulosic orlignocellulosic material has an α-cellulose content of less than about93 percent.
 8. The method of claim 1, wherein the fibrous cellulosic orlignocellulosic material comprises cotton.
 9. The method of claim 1,wherein exposing the garment body to the particle beam increases themolecular weight of the cellulosic or lignocellulosic material.
 10. Themethod of claim 1, further comprising quenching the irradiated textile.11. The method of claim 10 wherein quenching is performed in thepresence of a gas selected to react with radicals present in theirradiated textile.
 12. The method of claim 1, wherein the fibrouscellulosic or lignocellulosic material is selected from the groupconsisting of flax, hemp, jute, abaca, sisal, wheat straw, LF, ramie,bamboo fibers, cuprammonium cellulose, regenerated wood cellulose,lyocell, cellulose acetate, and blends thereof.